U.S. patent application number 13/968410 was filed with the patent office on 2014-02-20 for connection arrangement and crossmember.
The applicant listed for this patent is PROGRESS-WERK Oberkirch AG. Invention is credited to Stephan Kasper, Franz Mayer, Arnaud Offner, Hansjoerg Schmieder, Daniel Vogel.
Application Number | 20140049075 13/968410 |
Document ID | / |
Family ID | 50029425 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140049075 |
Kind Code |
A1 |
Kasper; Stephan ; et
al. |
February 20, 2014 |
CONNECTION ARRANGEMENT AND CROSSMEMBER
Abstract
A connection arrangement for connecting two tube pieces of a
crossmember for a vehicle has a first attachment element made of a
first material, wherein the first attachment element is provided
for a solid material-bonded connection to at least a first tube
piece which comprises the first material. Furthermore, the first
attachment element has a second attachment element which is
fastened to the first attachment element, wherein the second
attachment element consists essentially of a second material
differing from the first material, wherein the second attachment
element is provided for a solid material-bonded connection to a
second tube piece which comprises the second material. Furthermore,
a crossmember has such a connection arrangement.
Inventors: |
Kasper; Stephan; (Oberkirch,
DE) ; Mayer; Franz; (Oberkirch, DE) ; Offner;
Arnaud; (Soufflenheim, FR) ; Schmieder;
Hansjoerg; (Oberkirch-Zusenhofen, DE) ; Vogel;
Daniel; (Kappelrodeck, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PROGRESS-WERK Oberkirch AG |
Oberkirch |
|
DE |
|
|
Family ID: |
50029425 |
Appl. No.: |
13/968410 |
Filed: |
August 15, 2013 |
Current U.S.
Class: |
296/205 ;
296/29 |
Current CPC
Class: |
B62D 27/02 20130101;
Y10T 403/57 20150115; B62D 21/02 20130101; B62D 25/145
20130101 |
Class at
Publication: |
296/205 ;
296/29 |
International
Class: |
B62D 27/02 20060101
B62D027/02; B62D 21/02 20060101 B62D021/02 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 17, 2012 |
DE |
10 2012 016 268.5 |
Claims
1. A connection arrangement for connecting two tube pieces of a
crossmember for a vehicle, comprising a first tube having a first
material, a first attachment element essentially made of the first
material and arranged to be solidly connected to the first tube
piece in material-bonded manner, a second tube having a second
material different from the first material, a second attachment
element essentially made of the second material and fastened to the
first attachment element, the second attachment element arranged to
be solidly connected to the second tube piece in material-bonded
manner.
2. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element are
arranged in succession aligned in the longitudinal direction.
3. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element are
tubular.
4. The connection arrangement according to claim 3, wherein the
first attachment element and the second attachment element have
different wail thicknesses.
5. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element have
different cross sections.
6. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element are
connected to one another in a form-fitting manner.
7. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element are
connected to one another through a screw-connector.
8. The connection arrangement according to claim 7, wherein the
screw-connector has a screw element and a locking element, wherein
the screw element extends in an interior of the first attachment
element and of the second attachment element and is held against an
inner face of a first end wall of the first attachment element,
wherein the locking element is held against a further inner face of
a second end wall of the second attachment element lying opposite
to the first end wall of the first attachment element, and is
screwed to the screw element.
9. The connection arrangement according to claim 1, further
comprising a partition element for avoiding contact corrosion
between the first attachment element and the second attachment
element, which is arranged between the first attachment element and
the second attachment element.
10. The connection arrangement according to claim 1, wherein the
first attachment element is inserted partially into the second
attachment element, such that the first attachment element and the
second attachment element peripherally touch one another in an
overlap region over a partial length of the first attachment
element and of the second attachment element, the first attachment
element and the second attachment element being connected to one
another in the overlap region.
11. The connection arrangement according to claim 10, wherein the
first attachment element and the second attachment element are
connected to one another by at least one of crimping and
flanging.
12. The connection arrangement according to claim 10, wherein the
first attachment element receives the first tube piece in an
overlapping manner along a partial length of the first attachment
element for connecting the first attachment element to the first
tube piece in material-bonded manner.
13. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element are
connected to one another in a material-bonded manner.
14. The connection arrangement according to claim 1, wherein the
first attachment element and the second attachment element are
connected to one another by a sleeve-shaped connection element,
which surrounds the first attachment element and the second
attachment element at least partially peripherally.
15. The connection arrangement according to claim 14, wherein the
sleeve-shaped connection element has at least one silt, which runs
in the longitudinal direction of the connection element and
interrupts the sleeve-shaped connection element in its peripheral
extension.
16. The connection arrangement according to claim 14, wherein the
first attachment element, the second attachment element and the
sleeve-shaped connection element are connected to one another in
material-bonded manner through at least one adhesive
connection.
17. The connection arrangement according to claim 14, wherein the
first attachment element, the second attachment element and the
sleeve-shaped connection element are connected to one another in
material-bonded manner through at least one weld.
18. A crossmember for a vehicle, comprising a first tube having a
first material, a first attachment element essentially made of the
first material and solidly connected to the first tube piece in
material-bonded manner, a second lube having a second material
different from the first material, a second attachment element
essentially made of the second material and fastened to the first
attachment element, the second attachment element being solidly
connected to the second tube piece in material-bonded manner.
19. The crossmember according to claim 18, wherein the first tube
piece is connected to the first attachment element and the second
tube piece is connected to the second attachment element through at
least one of welding and adhesive bonding.
20. The connection arrangement according to claim 1, wherein the
first material is chosen from a group consisting of steel, a steel
alloy, and the second material is chosen from a group consisting of
a light metal, a light metal alloy, aluminum, aluminum alloy.
21. The crossmember according to claim 18, wherein the first
material is chosen from a group consisting of steel, a steel alloy,
and the second material is chosen from a group consisting of a
light metal, a light metal alloy, aluminum, aluminum alloy.
Description
CROSSREFERENCE TO RELATED APPLICATION
[0001] This application claims priority from German patent
application No. 10 2012 016 268.5 filed on Aug. 17, 2012. The
entire content of this priority application is incorporated herein
by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to connection arrangements for
connecting two tube pieces of a crossmember for a vehicle. Further,
the invention relates to crossmembers for vehicles having such a
connection arrangement.
[0003] From the document WO 2008/034522 A1, a connection
arrangement is known which has an attachment element in the form of
a socket, which consists universally of the same material and at
the longitudinal ends of which tube pieces are inserted, these
being adhesively bonded to the socket in order to thus produce the
crossmember.
[0004] The connection arrangement according to the invention and
the crossmember according to the invention can be used, in
particular as a component of a motor vehicle body, without loss of
generality. As part of the motor vehicle body, the crossmember is
arranged between what are known as the A-pillars in the region
underneath the windscreen, running approximately horizontally. The
crossmember serves for fastening the dashboard, the crossmember
additionally stiffening the dashboard, which usually consists of
plastic.
[0005] The crossmember has to have a high flexural rigidity, not
only owing to its function of bracing the dashboard, but also on
account of its function as a vehicle body component. A high
flexural rigidity of the crossmember contributes not only
ultimately to an increased safety of the motor vehicle and to
protection of the occupants in the event of an accident. On the
other hand, it is desirable nowadays to save weight in the case of
body components in order to lower the energy consumption of motor
vehicles.
[0006] Crossmembers are occasionally made up of at least two tube
pieces which have to be solidly connected to one another. In order
to take into account the demand for the highest possible stability
and torsional and flexural rigidity, on the one hand, and the
lowest possible weight, on the other hand, different materials of
differing density are occasionally used for the various tube
pieces.
[0007] In order to take into account the needs for the lowest
possible weight, and without a loss in stability, the tube piece
running in the region of the steering column can be produced from
steel, whereas the crossmember on the passenger side can have a
lighter tube piece made from a light metal, in particular made of
aluminum, with both tube pieces being fixedly connected to one
another.
[0008] Within the context of the present invention, the term "tube"
or "tube piece" is to be understood in general terms, it being
possible within the context of the present invention for these to
have any desired cross-sectional shape, which may be round, angular
or oval, for example. Similarly encompassed is a configuration of a
tube piece which is open laterally in cross section, for example in
a C, T or L shape and the like.
[0009] The crossmember disclosed in document WO 2008/034522 is
based on the concept of solidly connecting the individual tube
pieces, which typically consist of different materials, in
particular of light metals or composite materials, by means of a
respective socket arranged between two tube pieces and by an
adhesive connection between the socket and the tubes. The socket is
in this case in the form of a single-part magnesium die-cast
component.
[0010] A connection between the socket and the tube pieces by
adhesive bonding is, however, less suitable for large-scale or mass
production of crossmembers owing to the time and-cost involved in
this connection technique. In addition, this connection technique
has the disadvantage that material-bonding joining processes common
for tube pieces consisting of metal, in particular steel tubes or
aluminum tubes, for example welding processes, and the associated
cost-effective production processes cannot be used for the
production of crossmembers. This is because it is not readily
possible to simply weld tube pieces made of steel and aluminum to
the socket made of diecast magnesium. This is disadvantageous with
respect to the production costs for a crossmember.
[0011] Document EP 2 112 054 A1 discloses a crossmember having a
crossmember tube piece made of steel on the driver side and a
crossmember tube piece made of aluminum on the passenger side, the
two crossmember tube pieces being welded to one another directly by
means of a CMT welded connection.
[0012] The connection of the crossmember parts made of steel and
aluminum by a CMT welded connection is disadvantageous since this
is complicated and expensive. In addition, a material-bonded welded
connection between aluminum and steel is to be considered
sceptically in terms of the stability of the crossmember.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide a
connection arrangement that can be produced in a time and costs
saving manner.
[0014] It is a further object of the present invention to provide a
connection arrangement which can be manufactured using common
material-bonding joining processes which are established for
metals.
[0015] It is a further object to provide a crossmember that can be
produced in a time and costs saving manner.
[0016] It is a further object of the present invention to provide a
crossmember which can be manufactured using common material-bonding
joining processes which are established for metals.
[0017] According to an aspect, a connection arrangement for
connecting two tube pieces of a crossmember for a vehicle is
provided, comprising a first tube having a first material, a first
attachment element essentially made of the first material and
arranged to be solidly connected to the first tube piece in
material-bonded manner, a second tube having a second material
different from the first material, a second attachment element
essentially made of the second material and fastened to the first
attachment element, the second attachment element arranged to be
solidly connected to the second tube piece in material-bonded
manner.
[0018] According to a further aspect, a crossmember for a vehicle
is provided, comprising a first tube having a first material, a
first attachment element essentially made of the first material and
solidly connected to the first tube piece in material-bonded
manner, a second tube having a second material different from the
first material; a second attachment element essentially made of the
second material and fastened to the first attachment element, the
second attachment element being solidly connected to the second
tube piece in material-bonded manner.
[0019] The connection arrangement according to the invention has a
first attachment element and a second attachment element which are
fastened to one another. The first attachment element consists
essentially of a first material and the second attachment element
consists essentially of a second material. The second material
differs from the first material. The connection arrangement is
arranged between two tube pieces, the first attachment element
being connected to the first tube piece in material-bonded manner
and the second attachment element being connected to the second
tube piece in material-bonded manner. Here, "consisting essentially
of the first material" or "consisting essentially of the second
material" is to be understood as meaning that the first attachment
element and the second attachment element consist of the first or,
respectively, second material at least in their joint region of the
material-bonded connection to the first or, respectively, second
tube piece. However, the attachment elements can also consist
entirely of the respective material.
[0020] With the connection arrangement according to the invention,
it is now advantageously possible to connect the first attachment
element to the first tube piece in material-bonded and
mono-material or sorted manner and to connect the second attachment
element to the second tube piece in material-bonded and
mono-material or sorted manner. If, for example, the intention is
to connect a tube piece made of aluminum to a tube piece made of
steel, aluminum is chosen for the first attachment element and
steel is chosen for the second attachment element, such that
aluminum is to be connected with aluminum in material-bonded manner
and steel is to be connected to steel in material-bonded manner,
for which purpose common welding processes which are readily
controllable can be employed. The crossmember according to the
invention can therefore be produced cost-effectively and involving
little time.
[0021] The two attachment elements can be formed from solid
material or else can be hollow, the geometry of the attachment
elements being adapted to the geometry of the tube pieces to be
connected. The material-bonded connection between the attachment
elements and the tube pieces can be realized edge to edge or with
an overlap.
[0022] The connection of the first attachment element to the second
attachment element and the material-bonded connection of the first
attachment element to the first tube piece and of the second
attachment element to the second tube piece additionally ensure
that the crossmember has a high flexural rigidity in the region in
which the two tube pieces are connected.
[0023] In addition, the connection arrangement according to the
invention can be introduced into the production process of a
crossmember as a prefabricated part. The connection arrangement
according to the invention is suitable specifically for being
produced temporally and locally independently of the final
production of the crossmember, which additionally contributes to a
reduction in the time and costs involved in the production of the
entire crossmember. The connection arrangement according to the
invention can have a small size and can be shipped in large
quantities with a smell shipping volume to the site of final
production of the crossmembers, as a result of which shipping costs
are kept low.
[0024] The advantages of the crossmember according to the invention
for a vehicle become apparent from the aforementioned advantages of
the connection arrangement, since the latter is suitable in
particular for the production of a crossmember.
[0025] In a preferred configuration of the connection arrangement,
the first attachment element and the second attachment element are
arranged in succession aligned in the longitudinal direction.
[0026] This configuration is advantageously suitable for an aligned
connection of two tube pieces. Owing to an aligned arrangement of
the first tube piece and of the second tube piece and also of the
first attachment element and of the second attachment element, the
tube pieces can be connected without an overlapping region of the
tube pieces on account of the interposed connection arrangement,
which contributes to a reduction in the use of material and
therefore to a reduction in costs.
[0027] In a further preferred configuration, the first attachment
element and the second attachment element are tubular.
[0028] Compared to a configuration of full material, a tubular
configuration of the first and second attachment elements achieves
the advantage of a saving in weight of the connection arrangement.
In addition, the tube pieces to be connected can be pushed into the
attachment elements and can therefore be connected to the
attachment elements in material-bonded manner with an overlap, as a
result of which the stability of the material-bonded connection can
be increased.
[0029] In a further preferred configuration, the first attachment
element and the second attachment element have different wall
thicknesses.
[0030] By way of example, the attachment element made of the
relatively hard material, for example of steel, can be produced
with a smaller wall thickness than the attachment element made of
the relatively soft material, for example aluminum, such that this
measure likewise advantageously contributes to a saving in weight,
without this being accompanied by a loss in stability.
[0031] In a further preferred configuration, the first attachment
element and the second attachment element have different cross
sections, in particular cross-sectional profiles or cross-sectional
diameters.
[0032] In this configuration, tube pieces having different
cross-sectional diameters or cross-sectional profiles can
advantageously be connected to one another. Crossmembers in the
manufacture of vehicle bodies often have portions with different
cross-sectional profiles or cross-sectional diameters over the
length of the crossmember, in order to rule out resonances in the
crossmember during operation of the vehicle.
[0033] In a further preferred configuration, the first attachment
element and the second attachment element are connected to one
another in a form-fitting manner.
[0034] One advantage of this configuration is that the different
materials of the first attachment element or of the second
attachment element play a subordinate role for the connection of
said elements to one another, since material--bonded fastening of
the attachment elements to one another can be dispensed with in
this configuration. By way of example, a form-fitting connection of
the attachment elements can be realized by screwing or screwing
means.
[0035] In a further preferred configuration of the connection
arrangement, the first attachment element and the second attachment
element are connected to one another by a screwed connection.
[0036] A screwed connection represents on the one hand a stable
connection technique and on the other hand a connection technique
which is easy to handle in terms of assembling the connection
arrangement, this connection technique also making it possible to
compensate for tolerances.
[0037] In a preferred embodiment, the screwed connection has a
screw element and a locking element, wherein the screw element
extends in the interior of the first attachment element and of the
second attachment element and is held against an inner face of a
first end wall of the first attachment element, wherein the locking
element is held against an inner face of a second end wail of the
second attachment element lying opposite to the first end wail of
the first attachment element, and is screwed to the screw
element.
[0038] This embodiment constitutes a particularly simple and
cost-effective form-fitting and also force-fitting connection
between the first attachment element and the second attachment
element which has both a very high compressive and tensile strength
in the longitudinal direction of the connection arrangement and
also a high flexural rigidity transverse to the longitudinal
direction. With this configuration of the connection arrangement,
it is additionally possible in a particularly simple manner, if the
distance between the ends of the tube pieces which m to be bridged
by the connection arrangement is subjected to tolerances, to
compensate for such tolerances by spacer washers introduced between
the first and the second attachment elements.
[0039] A further advantage of this embodiment is that the screwed
connection arranged in the interior of the, in this case hollow,
attachment elements is protected to the greatest possible extent
against external influences.
[0040] In a further preferred configuration, a partition element
for avoiding contact corrosion between the first attachment element
and the second attachment element is arranged between the first
attachment element and the second attachment element.
[0041] This measure advantageously increases the long-term
stability of the connection arrangement by avoiding contact
corrosion between the two attachment elements. The use of a
partition element for avoiding contact corrosion is advantageous
particularly when the first attachment element and the second
attachment element consist of different metals with different
electrochemical properties, for example in the case of steel and
aluminum. A partition element of this type can be a galvanic
coating or a part which is inert towards the materials of the
attachment elements.
[0042] In a further preferred configuration, the first attachment
element is inserted partially into the second attachment element,
such that the first attachment element and the second attachment
element peripherally touch one another in an overlapping manner
over a partial length of the first attachment element and of the
second attachment element, wherein the first attachment element and
the second attachment element are fastened to one another in the
overlap region by forming, in particular by crimping or
flanging.
[0043] This embodiment, too, constitutes a form-fitting connection
of the two attachment elements to one another. One advantage of
this configuration is that the connection between the first
attachment element and the second attachment element by means of
forming, in particular cold forming, is a very simple connection
which can be produced cost-effectively. In addition, since the
first attachment element is inserted partially into the second
attachment element along the second partial length, an increased
flexural rigidity is achieved transversely to the longitudinal
direction of the connection arrangement, since the attachment
elements are supported against one another transversely to the
longitudinal direction.
[0044] In a further preferred configuration of the aforementioned
measure, the first attachment element has an overlap region for
receiving the first tube piece in an overlapping manner along a
partial length of the first attachment element and for connecting
the first attachment element to the first tube piece in
material-bonded manner.
[0045] Owing to the overlapping reception of the first tube piece
on the first attachment element preferably over the entire
periphery, the inner face of the first tube piece and the outer
face of the first attachment element touch one another in the first
overlap region, advantageously resulting in a high flexural
rigidity of the connection of the tube piece with the connection
arrangement transversely to the longitudinal direction.
[0046] In a further preferred alternative configuration, the first
attachment element and the second attachment element are connected
to one another in material-bonded manner.
[0047] One advantage of this configuration is that the first
attachment element and the second attachment element are connected
to one another in particular with a high torsional rigidity. By way
of example, if the first attachment element is made of aluminum and
the second attachment element is made of steel, the two attachment
elements can be connected by a material-bonded join, for example an
EMPT join.
[0048] In a further preferred configuration, the first attachment
element and the second attachment element are connected to one
another by a strip-shaped or sleeve-shaped connection element,
which surrounds the first attachment element and the second
attachment element at least partially peripherally.
[0049] The fastening of the two attachment elements by means of a
strip-shaped or sleeve-shaped connection element likewise
constitutes a particularly simple and cost-effective type of
fastening.
[0050] In the case of a strip-shaped connection element, this can
be produced from a composite material, in particular a glass fibre
composite material (GRP) or a carbon fibre composite material
(GRP). The strip-shaped connection element is preferably wound
around the attachment elements in a plurality of layers. It can be
self-adhesive or can be bonded to the attachment elements by
separate adhesive.
[0051] A sleeve-shaped connection element can be, for example, a
metal sleeve which is preferably adhesively bonded onto the
attachment elements.
[0052] The choice of a suitable overlap region between the
strip-shaped or sleeve-shaped connection element and the first
attachment element and also the second attachment element makes if
possible to adapt the flexural rigidity of the connection
arrangement to the respective requirements of the crossmember. In
addition, a connection of the attachment elements, which in the
present case consist of different metals, to a strip-shaped
connection element made of a non-metal is non-critical in terms of
contact corrosion. This also applies to the configuration of the
connection element in the form of a metallic sleeve, if the latter
is adhesively bonded onto the attachment elements by means of a
layer of adhesive such that there is no contact between the sleeve
and the attachment elements.
[0053] In addition, the fastening of the first attachment element
to the second attachment element by the strip-shaped or by the
sleeve-shaped connection element gives rise to the advantage that
these connection elements are also suitable for being able to
compensate for large tolerances in the distance between the first
tube piece and the second tube piece, because the attachment
elements can be fastened to one another spaced apart
differently.
[0054] In the case of a sleeve-shaped connection element, the
latter preferably has at least one partition line, which runs in
the longitudinal direction of the connection element and interrupts
the sleeve-shaped connection element in its peripheral extent.
[0055] The at least one partition line firstly makes it possible to
easily adapt the sleeve to the attachment elements in terms of
diameter by expanding or compressing, and secondly the partition
line can be utilized as an adhesive gap advantageously for
introducing adhesive between the sleeve and the attachment
elements. The partition line can tee continuous or interrupted in
the longitudinal direction of the sleeve.
[0056] In a further configuration of the aforementioned alternative
configurations, the first attachment element, the second attachment
element arid the strip-shaped or sleeve-shaped connection element
are connected to one another in material-bonded manner through at
least one adhesive connection.
[0057] An adhesive connection between the first attachment element,
the second attachment element and the strip-shaped or sleeve-shaped
connection element is easy to implement end can advantageously
contribute to the avoidance of contact corrosion.
[0058] However, it is similarly possible, as provided in an
alternative configuration to that mentioned above, that the second
attachment element and the sleeve-shaped connection element are
connected to one another in material-bonded manner through at least
one welded connection, in particular a CMT welded connection.
[0059] A material-bonded connection of the first attachment
element, of the second attachment element and of the sleeve-shaped
connection element by a CMT welded connection constitutes a
possible connection technique.
[0060] In general terms, the advantages for the crossmember
according to the invention become evident from the advantages of
the connection arrangement according to the invention in one or
more of the aforementioned configurations. Preferably, the first
tube piece of the crossmember is formed as a steel tube and the
second tube piece of the crossmember is formed as a light metal
tube, in particular as an aluminum tube, where in this case the
first attachment element is produced from steel and the second
attachment element is produced from light metal, in particular
aluminum.
[0061] By choosing substantially the same material for the first
attachment element and the first tube piece and also for the second
attachment element and the second tube piece, it is possible to
ensure that the first tube piece can be welded to the first
attachment element and the second tube piece can be welded to the
second attachment element in a mono-material or sorted manner,
leading to an increased quality of the joint between the connection
arrangement and the tube pieces. In addition, for connecting the
first attachment element to the first tube piece and the second
attachment element to the second tube piece, it is possible to draw
on already existing and established processes for connecting
crossmember components, which makes simple and cost-effective
production of the crossmember possible.
[0062] The connection arrangement according to the invention in the
embodiments described above additionally makes tolerance
compensation possible, in that the compensation of gaps in the
longitudinal direction and also transversely thereto can be ensured
by an appropriate configuration of the connection arrangement in
respect of the cross-sectional profile, the cross-sectional
diameter and/or toe connection between the attachment elements.
[0063] On account of the fact that the connection arrangement can
be prefabricated as a separate part which is welded to the first
and the second tube pieces during the final production of the
crossmember, in principle the individual production processes of
the crossmember can be locally and temporally decoupled, which on
the one hand results in a reduction in the time and costs involved
and on the other hand makes it possible to flexibly adapt
fluctuations in quantities or models which possibly arise within
existing processes.
[0064] Further advantages and features will become apparent from
the following description and the accompanying drawing.
[0065] It is self-evident that the features mentioned above and
those still to be explained below can be used not only in the
combination given in each case, but rather also in other
combinations or on their own, without departing from the scope of
the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] Exemplary embodiments of the invention are shown in the
drawings and will be described in more detail with reference
thereto. In the drawings:
[0067] FIG. 1 shows a crossmember, having a tube arrangement which
has a first tube piece and a second tube piece and also a
connection arrangement arranged therebetween for connecting the two
tube pieces, in a perspective illustration;
[0068] FIG. 2 shows a sectional illustration of the connection
arrangement shown in FIG. 1 in a view enlarged compared to FIG.
1;
[0069] FIG. 3 shows a further exemplary embodiment of a connection
arrangement in a sectional illustration similar to that in FIG.
2:
[0070] FIG. 4 shows yet another exemplary embodiment of a
connection arrangement in a side view;
[0071] FIG. 5 shows yet another exemplary embodiment of a
connection arrangement in a view similar to that in FIG. 4.
DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS
[0072] FIG. 1 shows a crossmember provided with the general
reference sign 10, for a motor vehicle. The crossmember 10 is used
in a motor vehicle for bracing a dashboard (not shown). The
crossmember 10 is arranged in a motor vehicle in the region
underneath the windscreen between the vertically running A-pillars
and is fastened to the latter.
[0073] The crossmember 10 has a tube arrangement 12 having a first
tube piece 14 and a second tube piece 16.
[0074] The first tube piece 14 and the second tube piece 16 have a
circular cross section in the exemplary embodiment shown. It is
self-evident that the first tube piece 14 and the second tube piece
16 can also have cross-sectional profiles which differ from a
circular cross section. In the exemplary embodiment shown, the
first tube piece 14 has a smaller cross-sectional diameter than the
second tube piece 16, it being possible for the tube piece 16 to
have a greater wall thickness than the first tube piece 14. It is
self-evident that the cross-sectional diameter and/or the wall
thickness of the tube pieces 14 and 16 can have any desired
feasible dimensions. It is similarly self-evident that the tube
pieces 14 and/or 16 can also have one or more bends or a curved
profile instead of being straight, as is shown.
[0075] At its two ends, the crossmember 10 has a first fastening
element 18 and a second fastening element 20 for attaching the
crossmember 10 to the two A-pillars (not shown).
[0076] When installed in a motor vehicle, the first fastening
element 18 forms the left-hand end of the crossmember 10, as seen
from the driver, and the second fastening element 20 forms the
right-hand end of the crossmember 10.
[0077] At ends 19, 21 remote from the fastening elements 18 and 20,
the first tube piece 14 and the second tube piece 16 are connected
to one another solidly, in particular with flexural and torsional
rigidity, by a connection arrangement 22.
[0078] In the exemplary embodiment shown in FIG. 1 and FIG. 2, the
connection arrangement 22 has a first tubular attachment element
24, which is connected in material-bonded manner to the end 19 of
the first tube piece 14 by a welded connection 26 formed over the
entire periphery. Both the first attachment element 24 and the
first tube piece 14 are in this case produced from steel, so that
these are welded to one another in a mono-material or sorted
manner.
[0079] The connection arrangement 22 also has a second tubular
attachment element 28, which lies opposite to the first attachment
element 24 and is connected to the end 21 of the second tube piece
16 by a second welded connection 30, which is formed over the
entire periphery of the second tube piece 16 and of the second
attachment element 28. In the present case, the second attachment
element 28 and the second tube piece 16 are likewise produced from
the same material, in particular from aluminum, so that these are
welded to one another in a mono-material or sorted manner. It is
self-evident that the attachment elements 24, 28 and the tube
pieces 14, 16 can also consist of a steel alloy or of a light metal
alloy, in particular of an aluminum alloy.
[0080] The first tube piece 14, the second tube piece 16 and also
the first and second attachment elements 24, 28 are arranged in
succession along a longitudinal axis 32 of the crossmember 10. It
is self-evident that, on account of this arrangement, the
longitudinal axis of the first attachment element 24 corresponds
substantially to the longitudinal axis 32 of the crossmember
10.
[0081] In the exemplary embodiment shown in FIG. 1 and FIG. 2, the
first attachment element 24 is connected to the second attachment
element 28 solidly, in particular with a form fit or force fit, by
a screwed connection 33 (cf. FIG. 2).
[0082] The connection between the first and second attachment
elements 24, 28 and also the attachment thereof to the first and
second tube pieces 14, 16 will be described in more detail
hereinbelow.
[0083] FIG. 2 shows a sectional illustration of the connection
arrangement 22 shown in FIG. 1 in an illustration enlarged compared
to FIG. 1, and also the attachment of the first attachment element
24 and of the second attachment element 28 of the connection
arrangement 22 to the first and second tube pieces 14, 16 of the
crossmember by the welded connections 26, 30 formed over the entire
periphery.
[0084] In the present exemplary embodiment, the second attachment
element 28 is designed with an enlarged wall thickness and with an
enlarged cross section compared to the first attachment element 24,
in order to achieve a stability comparable to the first attachment
element 24 consisting of steel.
[0085] The first attachment element 24 has a first end wail 34 and
the second attachment element 28 has a second end wall 36, these
walls being arranged lying opposite one another and being connected
by the screwed connection 33, which has a screw element 38 and a
locking element 40. The screw element 38 is screwed to the locking
element 40, the screw element 38 and the locking element 40 being
held in each case against the inner face of the first and,
respectively, second end walls 34, 36. The first and the second end
walls 34, 36 have through holes 41, which are flush with one
another along the longitudinal axis 32 and through, which the screw
element 38 extends. The end walls 34, 36 can in this case be formed
on the attachment elements 24, 28 by deep drawing or can be joined
as separate parts thereto, for example by welding.
[0086] It is self-evident that the screwed connection 33 between
the first and second attachment elements 24, 28 can also be formed
by a threaded bolt, which is screwed with a respective locking
element onto the inner faces of the end wails 34, 36. The
connection by a bolt which is fixed to one of the end walls 34, 36
and is fastened with a locking element fixed to the opposite inner
face of one of the end walls 34, 36 also represents a possible
embodiment of a screwed connection.
[0087] Washers 42, 44 are additionally introduced between the screw
element 38 and the first end wall 34 and also between the second
end wall 36 and the locking element 40. These washers serve to
prevent contact corrosion between the screw element 38 and the
first attachment element 24 and also between the locking element 40
and the second attachment element 28.
[0088] A partition element 46, through which the screw element 38
likewise engages, is provided between the first attachment element
24 and the second attachment element 28. Here, the partition
element 46 likewise serves for avoiding contact corrosion or
mechanical decoupling between the first attachment element 24 and
the second attachment element 28. In addition, one such partition
element or a plurality of such partition elements can be used to
set the length of the connection arrangement 22, for example for
tolerance compensation when assembling the crossmember 10. It is
self-evident that the material of the spacer washers 42, 44 and
also of the partition element 46 can be matched to the materials
used in each case for the first and second attachment elements 24,
28 with a view to avoiding contact corrosion.
[0089] The first attachment element 24 is connected to the second
attachment element 28 fixedly in terms of tensile and compressive
loading in the direction of the longitudinal axis 32 and also with
flexural rigidity transverse to the longitudinal axis 32 by the
screwed connection consisting of the screw element 38 and the
locking element 40. The same also applies to the first and second
tube pieces 14, 16 of the crossmember 10, which are fastened
respectively by the first and second welded connections 28, 30 to
the first attachment element 24 and to the second attachment
element 28.
[0090] The attachment elements 24, 28 are arranged along the
longitudinal axis 32 axially flush respectively with one another
and with the first and second tube pieces 14, 16. If is
self-evident, however, that one of the attachment elements 24, 28
can also be offset in relation to the longitudinal axis 32 and is
fixedly connected to the respective other attachment element by the
screw element 38 and the locking element 40.
[0091] In principle, the cross sections of the substantially
tubular first and second attachment elements 24, 28 are matched to
the cross sections of the first and second tube pieces 14, 16 of
the crossmember 10 in such a manner that these can be solidly
connected with the welded connections 26, 30. In the present case,
the cross section and the wall thickness of the first attachment
element 24 correspond approximately to those of the first tube
piece 14 and the wall thickness and the cross section of the second
attachment element 28 correspond approximately to those of the
second tube piece 16. It is self-evident that the cross sections of
the attachment elements 24, 28, and also the wall thicknesses
thereof, can also be embodied to be significantly smaller or larger
with respect to the respectively corresponding tube piece 14, 16,
such that either the first or second attachment element 24, 28
overlaps the respectively corresponding first tube piece 14 or
second tube piece 16 over the entire periphery, or vice versa.
[0092] Therefore, given an approximately identical cross-sectional
diameter, the first tube piece 14 and the first attachment element
24 can be pushed into one another edge to edge, or, given different
cross-sectional diameters, they can be pushed into one another with
an overlap, and can be welded by the first welded connection 26
(not shown). The same also applies to the second tube piece 16,
which is welded to the second attachment element 28 by the second
welded connection 30. The welded connections 26, 30 can
additionally be matched to the gaps or steps which form between the
attachment elements 24, 28 and the tube pieces 14, 16 in any
desired configuration in terms of their shape and thickness.
[0093] FIG. 3 shows the tube arrangement 12 of the crossmember 10,
which has the first tube piece 14 and the second tube piece 16,
with a connection arrangement 22a modified with respect to FIGS. 1
and 2.
[0094] Parts or elements of the connection arrangement 22a which
are identical or comparable to parts or elements of the connection
arrangement 22 in FIGS. 1 and 2 are provided with the same
reference signs, supplemented by the letter a.
[0095] The connection arrangement 22a has a first attachment
element 24a, the driver-side end 50 of which is provided with a
first overlap region 52, which is formed over the entire periphery
and is matched to the profile of the first tube piece 14. In this
case, the overlap region 52 has a cross-sectional diameter which is
reduced compared to the cross-sectional diameter of the first tube
piece 14, such that the first tube piece 14 is received along a
partial length A over the entire periphery of the overlap region 52
of the first attachment element 24a. In this case, the overlap
region 52 of the first attachment element 24 extends along the
partial length A of the first tube piece 14, with an inner
peripheral surface of the first tube piece 14 bearing against the
entire periphery of an outer peripheral surface of the overlap
region 52, and the end 19 of the first tube piece 14 comes to bear
against a stop 55 formed over the entire periphery of the first
attachment element 24a.
[0096] The cross-sectional profile of the stop 55 and the
cross-sectional diameter of the stop 55 in this case correspond
approximately to the cross-sectional profile and the
cross-sectional diameter of the first tube piece 14, such that a
substantially stepless transition arises between the first tube
piece 14 and the stop 55 of the first attachment element 24a. The
first tube piece 14 is additionally connected in material-bonded
manner to the first attachment element 24a by a first welded
connection 26a in the region of the stop 55.
[0097] In addition, the first attachment element 24a has a second
overlap region 56, which is arranged at a passenger-side end 58 of
the first attachment element 24a. The second overlap region 58 has
a rib formation 60, formed over the entire periphery, with
elevation regions 62 and depression regions 64. Here, the elevation
regions 62 end depression regions 64 have a cross-sectional profile
which corresponds to the cross-sectional profile of the second
attachment element 28a. The cross-sectional diameter of the
elevation regions here corresponds approximately to the internal
diameter of the second attachment element 28a, whereas the
depression regions have a cross-sectional diameter which is smaller
than the cross-sectional diameter of the elevation-regions 62.
[0098] The second overlap region 56 is introduced into the second
attachment element 28a and extends along a partial length B along
the inner peripheral surface of the second attachment element 28a,
the second attachment element 28a coming to bear against the step
54.
[0099] The second attachment element 28a is connected in
material-bonded manner to the second overlap region 56 of the first
attachment element 24a. In this case, the second attachment element
28a is pushed into the depression regions 64 over the entire
periphery in the region of the rib formation 60, such that the
second attachment element 28a is connected to the first attachment
element 24a by crimping. Therefore, the first attachment element
24a is connected to the second attachment element 28a fixedly in
terms of tensile and compressive loading in the direction of the
longitudinal axis 32 and with flexural rigidity transverse to the
longitudinal axis 32. It is self-evident that the first attachment
element 24a can additionally be joined to the second attachment
element 28a in the region of the rib formation 60 in
material-bonded manner, in particular by an EMPT welded connection
(not shown).
[0100] The second attachment element 28a is additionally connected
to the passenger-side, second tube piece 16 at the end 21 thereof
in a form-fitting manner, in particular by a second welded
connection 30a.
[0101] In the present exemplary embodiment, the driver-side, first
tube piece 14 is produced from steel and the passenger-side, second
tube piece 16 is produced from a light metal, in particular
aluminum. Therefore, the welded connections 26a, 30a, which connect
the first tube piece 14 and the second tube piece 16 to the first
attachment element 24a and to the second attachment element 28a of
the connection arrangement 22a, form a mono-material or sorted
joint.
[0102] FIG. 4 is a sectional illustration showing the tube
arrangement 12 of the crossmember 10, which has the first tube
piece 14 and the second tube piece 16, with a connection
arrangement 22b modified with respect to FIGS. 1 to 3.
[0103] Parts or elements of the connection arrangement 22b which
are identical or comparable to parts or elements of the connection
arrangement 22 in FIGS. 1 and 2 are provided with the same
reference signs, supplemented by the letter b.
[0104] As in the exemplary embodiments described above, the
connection arrangement 22b is made up of a first attachment element
24b and a second attachment element 28b, which are connected
respectively to the end 19 of the first, driver-side tube piece 14
and the end 21 of the second, passenger-side tube piece 16 by a
first welded connection 26b and a second welded connection 30b.
[0105] Similarly to in the exemplary embodiments described above,
the first attachment element 24b and the first tube piece 14
consist essentially of steel and the second attachment element 28b
and the second tube piece 16 consist essentially of light metal, in
particular of aluminum. Therefore, the attachment elements 24b, 28b
are welded to the tube pieces 14, 16 in a mono-material or sorted
manner by the welded connections 20b, 30b.
[0106] The first attachment element 24b and the second attachment
element 28b and also the first and second tube pieces 14, 16 are
arranged in succession along the longitudinal axis 32. The
connection arrangement 22b has a sleeve-shaped connection element
66, which surrounds the first attachment element 24b along a
partial length C and the second attachment element 28b along a
partial length D at least partially peripherally, the
cross-sectional profile of the sleeve-shaped connection element 66
being matched substantially to the cross-sectional profile of the
first and second attachment elements 24b, 28b, and the
sleeve-shaped connection element 66 having a cross-sectional
diameter which is enlarged compared to the attachment elements 24b,
28b.
[0107] The sleeve-shaped connection element 66 has a partition line
68, by which the cross-sectional diameter of the sleeve-shaped
connection element 66 can be matched to the respective tube
diameter of the first end second attachment elements 24b, 28b. This
can be done, for example, by compressing or widening the connection
element 66.
[0108] However, it is self-evident that the sleeve-shaped
connection element 66 can also have further partition lines, for
example in the form of slots, such that the sleeve-shaped
connection element 66 is formed in particular as an arrangement of
half-shells or partial shells which surround the first and second
attachment elements 24b, 28b partially peripherally (not
shown).
[0109] The first attachment element 24b and the second attachment
element 28b are adhesively bonded to the sleeve-shaped connection
element 66 by a joining material 70, the joining material 70 being
introduced at least partially peripherally into the intermediate
spaces between the sleeve-shaped connection element 66 and the
attachment elements 24b, 28b. Therefore, the first attachment
element 24b is connected to the second attachment element 28b
fixedly in terms of tensile and compressive loading in the
direction of the longitudinal axis 32 and with flexural rigidity
transverse to the longitudinal axis 32. It is self-evident that the
flexural rigidity of the connection arrangement 22b can be
increased by enlarging the partial lengths C and D.
[0110] The first and second attachment elements 24b, 28b are joined
to one another in such a manner that a gap 72 formed over the
entire periphery is formed at the opposing end walls 34b, 36b of
the first and second attachment elements 24b, 28b.
[0111] The gap 72 prevents contact corrosion between the first
attachment element 24b and the second attachment element 28b. In
addition, owing to the dimension of the gap 72 and the geometrical
configuration thereof, a virtually arbitrary tolerance compensation
of the first and second attachment elements 24b, 28b can be carried
out during assembly of the crossmember 10 in virtually all
directions in space.
[0112] In the present exemplary embodiment, the connection element
66 consists essentially of a strip of sheet steel bent in a tubular
form. However, it is self-evident that the connection element 66
can also be shaped from a light metal sheet, in particular an
aluminum sheet. In addition, it is self-evident that the connection
element 66 can also consist of a fibre material, in particular of
carbon fibre mats or glass fibre mats, which is connected in
material-bonded manner by means of the joining material 70 to the
first and second attachment elements 24b, 28b, and can surround the
latter partially peripherally, but also over the entire periphery,
for example formed as a ribbon. In this respect, the fibre material
can likewise be connected to the first and second attachment
elements 24b, 28b as a prefabricated connection element or directly
together with the joining material 70 (not shown).
[0113] FIG. 5 shows the tube arrangement 12 of the crossmember 10,
which has the first tube piece and the second tube piece 16, with a
further exemplary embodiment of a connection arrangement 22c.
[0114] Parts or elements of the connection arrangement 22c which
are identical or comparable to parts or elements of the connection
arrangement 22 or 22b shown in FIGS. 1, 2 and 4 are provided with
the same reference signs, supplemented by the letter c.
[0115] The connection arrangement 22c likewise has a first
attachment element 24c and a second attachment element 28c. In the
present exemplary embodiment, the attachment elements 24c, 28c are
likewise connected in material-bonded manner, by a first and second
welded connection 26c, 30c, to the first end 19 of the first,
driver-side tube piece 14 and the end 21 of the second,
passenger-side tube piece 16. The first attachment element 24c and
the first tube piece 14 consist of steel and the second attachment
element 28c and the second tube piece 16 consist of a light metal,
in particular aluminum. Therefore, the attachment elements 24c, 28c
are welded to the tube pieces 14, 16 of the crossmember 10 in a
mono-material or sorted manner.
[0116] The first attachment element 24c is connected in
material-bonded manner, in particular by a CMT welded connection
74, to the second attachment element 28c in the region of a first
end wall 34c of the first attachment element 24c and of a second
end wall 36c lying opposite to the first end wall 34c. Therefore,
the first attachment element 26c is connected to the second
attachment element 28c solidly in terms of tensile and compressive
loading in the direction of the longitudinal axis 32 and with
flexural rigidity transverse to the longitudinal axis 32.
[0117] The connection arrangement 22c additionally has a
sleeve-shaped connection element 66c formed at least partially
peripherally along a partial length E of the first attachment
element 24c and along a further partial length F of the second
attachment element 28c. In this case, the sleeve-shaped connection
element 66c consists of a strip of galvanized sheet steel, which is
matched to the peripheral profiles of the first and second
attachment elements 24c, 28c and is connected to the first
attachment element 24c and the second attachment element 28c by
further welded connections 76, in particular likewise CMT welded
connections. The sleeve-shaped connection element 66c is in this
case formed partially peripherally and is welded to the first and
second attachment elements 24c, 28c. However, it is self-evident
that the sleeve-shaped connection element 66c can also be formed
over the entire periphery (not shown).
[0118] In addition, it is self-evident that the sleeve-shaped
connection element 66c can also be connected to the first and
second attachment elements 24c, 28c by adhesive bonding.
[0119] In general terms, it is to be noted that the configuration
features of the connection arrangement 22 to 22c as described in
connection with FIGS. 1 to 5 can be combined with one another as
desired. Thus, for example, in a variant of the connection
arrangement 22b in FIG. 2, the gap 72 can be closed by a CMT welded
connection, such that the first attachment element 24b and the
second attachment element 28b can be connected to one another at
the first and second end faces 34b, 36b, which increases both the
tensile and compressive strength along the longitudinal axis 32 and
also the flexural rigidity transverse to the longitudinal axis
32.
[0120] It is self-evident that the first and the second tube piece
14, 16 and also the first attachment elements 24 to 24c and the
second attachment elements 28 to 28c of the connection arrangements
22 to 22c can fundamentally have any desired cross-sectional
diameters and cross-sectional profiles, as long as the cross
sections are matched to one another in the region of the welded
connections 26 to 26c and also 30 to 30c.
[0121] Matched to one another means that the first and second
attachment elements 26 to 26c and 28 to 28c can have different
cross-sectional diameters compared to the tube pieces 14 and 16,
such that the first and second attachment elements 26 to 26c and 28
to 28c are either received one in another in an overlapping manner
or are connected to one another edge to edge in the region of the
welded connections 26 to 26c and 30 to 30c with the first and
second tube pieces 14, 16. The embodiment of the welded connections
26 to 26c and 30 to 30c can also be configured according to the
statements made in relation to FIG. 2.
[0122] The thickness of the walls of the first and second tube
pieces 14, 16 or of the attachment elements 24 to 24c and also 28
to 28c can be matched to the respective intended use, in particular
in terms of stability and rigidity of the crossmember 10. The
material chosen for the first and second tube pieces 14, 16 and
also for the first and second attachment elements 24 to 24c and
also 28 to 28c can also include virtually any desired steel alloys
and also light metal alloys, as long as it is ensured that the tube
pieces 14, 16 can be welded to the respectively corresponding
attachment elements 24 to 24c and also 28 to 28c by the welded
connections 26 to 26c and also 30 to 30c substantially in a single
variety.
* * * * *